&#34;l&#34; bracket closed wall connector

ABSTRACT

A closed wall connector is provided comprising an “L” shaped bracket. The “L” shaped bracket includes a horizontal leg and a vertical leg. The horizontal leg includes a first plurality of apertures. The vertical leg includes a second plurality of apertures. The closed wall connector also includes a first plurality of fasteners to connect the horizontal leg to a base, and a second plurality of fasteners to connect the vertical leg to a wall panel. A wall is also provided. The wall includes a wall panel including a bottom plate and sheathing and a closed wall connector. The bottom plate and sheathing of the wall panel are connected to the vertical leg of the closed wall connector with the second plurality of fasteners. A method of installing the wall is also provided.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional application No.filed on Dec. 31, 2018 for “L” BRACKET CLOSED WALL CONNECTOR, which isincorporated by reference as if fully set forth.

FIELD OF INVENTION

The present invention relates generally to the art of exterior walls ofbuildings, and more specifically to an apparatus that secures a wallpanel to the building and the method of installation thereof.

BACKGROUND

In a traditionally built exterior building wall, the structural frame ofthe wall is bolted to the foundation during construction. Anchor boltsfixed to the foundation secure the wall forms and other constructionportions to the concrete slab foundation. Most commonly, anchor boltsare cast-in-place in preset positions, wherein the bolt head is castinto the concrete and the threaded end extends out of the foundation.The structural frame of the wall is constructed by securing the bottomplate to the foundation. The bottom plate is secured by predrillingholes into the bottom plate. The size and placement of the holescorrespond with the position of the anchor bolts. The bottom plate isplaced flat on the concrete foundation with the threaded ends of theanchor bolts extending up through the holes of the bottom plate. The nutof the anchor bolt is screwed onto the bolt threads to secure the bottomplate. The remaining exterior wall components are then installed.

However, some wall systems are constructed from prefabricate wallpanels. A wall panel may be assembled with the structural frame attachedto the wall's interior and exterior components. In this case, after theprefabricated wall panel is placed onto the threaded ends of the anchorbolts, the anchor bolts are no longer accessible to screw the nut ontothe anchor bolt threads. Because the threads of the anchor bolts are nolonger accessible, there is no way to secure the prefabricated wallpanel to the anchor bolt or foundation.

Therefore, there is a need for a device and method to secureprefabricated wall panels to a foundation or base.

SUMMARY

A closed wall connector is provided comprising an “L” shaped bracket.The “L” shaped bracket includes a horizontal leg and a vertical leg. Thehorizontal leg includes a first plurality of apertures. The vertical legincludes a second plurality of apertures. The closed wall connector alsoincludes a first plurality of fasteners to connect the horizontal leg toa base through the first plurality of apertures, and a second pluralityof fasteners to connect the vertical leg to a wall panel through thesecond plurality of apertures. The base may be a floor, a ceiling, or afoundation.

A wall is also provided. The wall includes a closed wall connector and awall panel including a bottom plate, a top plate, and sheathing. Theclosed wall connector includes the details and embodiments previouslydiscussed. The bottom plate, top plate, and/or sheathing of the wallpanel are connected to the vertical leg of the closed wall connectorwith the second plurality of fasteners.

A method of installing the wall is also provided. The method includesreceiving the closed wall connector, connecting the horizontal leg ofthe closed wall connector to a base with a first plurality of fasteners,placing a wall panel onto the horizontal leg and adjacent to thevertical leg of the closed wall connector, and connecting the wall panelto the vertical leg with a second plurality of fasteners. The closedwall connector and the wall panel include the details and embodimentspreviously discussed.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed descriptionwill be better understood when read in conjunction with the appendeddrawings. For the purpose of illustration, there is shown in thedrawings different embodiments. It should be understood, however, thatthe teachings are not limited to the precise closed wall connector, wallpanel, and method shown.

FIG. 1A is an elevation view of a closed wall connector connected to afloor.

FIG. 1B is an elevation view of the closed wall connector connected to afoundation.

FIG. 1C is an elevation view of the closed wall connector connected to aceiling.

FIG. 2 is a plan view of the horizontal leg of the closed wall connectorshown in FIGS. 1A and 1C.

FIG. 3 is a plan view of the horizontal leg of the closed wall connectorshown in FIG. 1B.

FIG. 4 is a plan view of the vertical leg of the closed wall connectorshown in FIGS. 1A-1C.

FIG. 5 is an elevation view of a wall panel being placed in two closedwall connectors.

FIG. 6 is an elevation view of the wall panel connected to the closedwall connectors.

FIG. 7 is an elevation view of a bottom plate of the wall panelconnected to the closed wall connector.

FIG. 8 is an elevation view of the wall panel connected to the closedwall connector with base boards installed.

FIG. 9 is a flow chart of a method of installing the closed wallconnector and the wall panel.

DETAILED DESCRIPTION

A closed wall connector that quickly and easily connects a prefabricatedor closed wall panel to the building is provided. The closed wallconnector includes an “L” shaped bracket. The “L” shaped bracketincludes a horizontal leg and a vertical leg. The horizontal legincludes a first plurality of apertures. The vertical leg includes asecond plurality of apertures. A first plurality of fasteners connectsthe horizontal leg to a base through the first plurality of apertures.The base may be a foundation, floor, or ceiling of a building. A secondplurality of fasteners connects the vertical leg to a wall panel throughthe second plurality of fasteners. The wall panel may be prefabricated.The connector provides a way to connect a prefabricated or closed wallpanel to a foundation, floor, or ceiling of a building without accessingthe inside of the wall panel.

A wall is also provided. The wall includes a closed wall connector and awall panel including a bottom plate, a top plate, and sheathing. Theclosed wall connector includes the details and embodiments previouslydiscussed. The bottom plate, top plate, and/or sheathing of the wallpanel are connected to the vertical leg of the closed wall connectorwith the second plurality of fasteners.

A method of installing the wall panel is also provided. The methodincludes receiving the closed wall connector, connecting the horizontalleg of the closed wall connector to a base with a first plurality offasteners, placing a wall panel onto the horizontal leg and adjacent tothe vertical leg of the closed wall connector, and connecting the wallpanel to the vertical leg with a second plurality of fasteners. Themethod provides a simple and efficient way to connect a prefabricated orclosed wall panel to a foundation, floor, or ceiling, thereby decreasingthe time to construct and install an exterior wall of a building andcutting construction costs.

As shown in FIGS. 1A-1C, a closed wall connector 100 is provided. Theclosed wall connector 100 connects a closed wall panel or prefabricatedwall panel to a base 250 a, 250 b, 250 c. The closed wall connector 100includes an “L” shaped bracket 200. The “L” shaped bracket 200 includesa vertical leg 210 and a horizontal leg 220. The horizontal leg 220connects the closed wall connector 100 to the base 250 a, 250 b, 250 c.The horizontal leg 220 includes a first plurality of apertures 230. Thefirst plurality of apertures 230 is configured to receive a firstplurality of fasteners 240 a, 240 b. As shown in FIGS. 1A-1C, thehorizontal leg 220 is connected to a base 250 a, 250 b, 250 c by a firstplurality of fasteners 240 a, 240 b. The fasteners 240 a, 240 b connectthe horizontal leg 220 to the base 250 a, 250 b through the firstplurality of apertures 230. The shank of the fastener 240 a, 240 bextends through the first plurality of apertures 230 into the base 250a, 250 b, 250 c. The head of the first plurality of fasteners 240 a, 240b is tight against the horizontal leg 220 thereby securing the closedwall connector 100 to the base 250 a, 250 b, 250 c. The horizontal leg220 of the closed wall connector 100 may also include openings (notshown) for mechanical, electrical, and plumbing utilities. The openingsallow the mechanical, electrical, and plumbing utilities to run fromfloor to floor without interference. The vertical leg 210 is configuredto connect to the closed wall panel. The length of the vertical leg 210and horizontal leg 220 depend on the size needed to transfer loads fromthe closed wall panel to the base 250 a, 250 b, 250 c. The closed wallconnector 100 may be made from galvanized steel, aluminum, or anymaterial with sufficient strength to transfer loads from the closed wallpanel to the base 250 a, 250 b, 250 c.

FIG. 1A is an elevation view of a closed wall connector 100 connected toa floor 250 a. A fastener 240 a extends through an aperture 230 in thehorizontal leg 220 to connect the closed wall connector 100 to a base250 a. In FIG. 1A, the base 250 a is a floor of a building. The firstplurality of fasteners 240 a used to connect the horizontal leg 220 tothe floor 250 a may be any fasteners, such as screws or nails. Thefastener 240 a must have properties that allow the loads applied to theclosed wall panel to transfer to the floor 250 a.

FIG. 1B is an elevation view of the closed wall connector 100 connectedto a foundation 250 b. As shown in FIG. 1B, the base 250 b may be aconcrete foundation. The first floor closed wall panels are connected toa foundation 250 b. In this embodiment, the first plurality of fasteners240 b that connect the horizontal leg 220 to the foundation 250 b may beanchor bolts and nuts. The anchor bolt may be a post-installed concreteanchor or the anchor bolt may be a cast-in-place embedded concreteanchor, shown in phantom in FIG. 1B. The fastener 240 b must haveproperties that allow the loads applied to the closed wall panel totransfer to the base 250 b.

FIG. 1C is an elevation view of the closed wall connector 100 connectedto a ceiling 250 c. As shown in FIG. 1C, the base 250 c may be aceiling. In this embodiment, the fasteners 240 a connect the horizontalleg 220 of the closed wall connector 100 to the ceiling 250 c. Like theembodiment shown in 1A, the first plurality of fasteners 240 a may beany fasteners, such as screws. The fastener 240 a must have propertiesthat allow the loads applied to the closed wall panel to transfer to theceiling 250 c.

FIG. 2 is a plan view of the horizontal leg 220 of the closed wallconnector 100 shown in FIGS. 1A and 1C. The width W of the horizontalleg 220 may be approximately the same width as the closed wall panel.Alternatively, the width W of the horizontal leg 220 may be shorter thanthe closed wall panel and multiple closed wall connectors 100 may beused to connect the closed wall panel to the base 250 a, 250 b, 250 c.The plurality of apertures 230 a-n configured to receive fasteners 240 ato connect the horizontal leg 220 to the base 250 a, 250 c are spacedalong the horizontal leg 220. As shown in FIG. 2, there may be two rowsof apertures 230 a-n. Although FIG. 2 depicts two rows of apertures 230a-n, the horizontal leg 220 may include more or less rows of apertures230 a-n. The spacing and number of apertures 230 a-n correspond with thenumber of fasteners 240 a needed to secure the closed wall connector 100to the floor 250 a or ceiling 250 c of a building. Moreover, the spacingand number of apertures 230 a-n correspond with the number of fasteners240 a needed to transfer loads from the closed wall panel to the floor250 a or ceiling 250 c. The diameter of the apertures 230 a-ncorresponds to the diameter of the fastener 240 a.

FIG. 3 is a plan view of the horizontal leg 220 of the closed wallconnector 100 shown in FIG. 1B. The plurality of apertures 230 a-nconfigured to receive fasteners 240 b to connect the horizontal leg 220to the base or foundation 250 b are spaced along the horizontal leg 220.As shown in FIG. 2, there may be a single row of apertures 230 a-n.Although FIG. 2 shows a single row of apertures 230 a-n, the horizontalleg 220 may include additional rows. The spacing and number of apertures230 a-n correspond with the number of fasteners or anchor bolts 240 bneeded to secure the closed wall connector 100 to the foundation 250 bof a building. Moreover, the spacing and number of apertures 230 a-ncorrespond with the number of fasteners 240 b needed to transfer loadsfrom the closed wall panel to the foundation 250 b. The diameter of theapertures 230 a-n corresponds to the diameter of the anchor bolt 240 b.

FIG. 4 is a plan view of the vertical leg 210 of the closed wallconnector shown 100 in FIGS. 1A-1C. The vertical leg 210 of the closedwall connector 100 includes a second plurality of apertures 260 a-n. Thesecond plurality of apertures 260 a-n is configured to receive fasteners242 (not shown in FIG. 4). The fasteners 242 connect the closed wallpanel to the vertical leg 210. As shown in FIG. 4, there may be a singlerow of apertures 260 a-n. Although FIG. 4 shows a single row ofapertures 260 a-n, the vertical leg 210 may include additional rows. Thespacing and number of apertures 260 a-n correspond with the number offasteners 242 needed to secure the closed wall panel to the closed wallconnector 100. Moreover, the spacing and number of apertures 260 a-ncorrespond with the number of fasteners 242 needed to transfer loadsfrom the closed wall panel to the closed wall connector 100. Thediameter of the apertures 260 a-n corresponds to the diameter of thefasteners 242.

FIG. 5 is an elevation view of a wall panel 300 being placed in twoclosed wall connectors 100. The wall panel 300 may be a prefabricated orpre-assembled, closed wall assembly. The wall panel 300 includes atleast one bottom plate 310. Although one bottom plate 310 is shown inFIG. 5, the wall panel 300 may include two or three bottom plates 310.The wall panel 300 may also include at least one top plate 340. Thebottom plate 310 and top plate 340 may be made from any structurallyrigid material such as wood 2×4s or aluminum. The wall panel 300 alsoincludes sheathing 320. Additionally, the wall panel 300 may includedrywall 330. As shown in FIG. 5, the drywall 330 may be held up from thebottom of the wall panel 300 to facilitate the wall panel 300 andvertical leg 210 connection. The drywall 330 may also be held down fromthe top of the wall panel 300 to facilitate the wall panel 300 andvertical leg 210 connection. The drywall 330 may be extended to thebottom of the bottom plate 310 and to the top of the top plate 340 onthe non-sheathed side of the wall panel 300. As shown in FIG. 5, thedepth of the “L” shaped bracket 200 may correspond to the depth of thewall panel 300. The “L” shaped bracket 200 may be a continuous bracketthe width of the wall panel 300.

FIG. 6 is an elevation view of the wall panel 300 connected to theclosed wall connectors 100. As shown in FIG. 6, the sheathing 320 of thewall panel 300 butts up against the vertical leg 210 of the “L” shapedbracket 200. The vertical leg 210 includes the second plurality ofapertures 260. A second plurality of fasteners 242 connects the closedwall connector 100 to the wall panel 300. The shank of the fastener 242extends through the aperture 260 into the wall panel 300 and the head ofthe fastener 242 is tight against the vertical leg 210. The secondplurality of fasteners 242 extends through the second plurality ofapertures 260 and through the sheathing 320 and into the bottom plate310 and/or top plate 340 of the wall panel 300. The plurality offasteners 242 can be any shear fastener such that the shear load appliedto the wall panel 300 is transferred to the closed wall connector 100and base 250 a, 250 b, 250 c.

FIG. 7 is an elevation view of a bottom plate 310 of the wall panel 300connected to the closed wall connector 100. FIG. 7 depicts the bottomplate 310 and sheathing 320 connected to the vertical leg 210 of theclosed wall connector 100, wherein the first plurality of fasteners 240b is anchor bolts and nuts and the base 250 b is a concrete foundation.Because the end of the anchor bolt and nut may be bulky and protrude upfrom the horizontal leg 220 of the closed wall connector 100, the bottomof the bottom plate 310 may be routed out to create a space 350 to fitover the head and nut of the anchor bolts 240 b. The bottom of thebottom plate 310 may have a space 350 to accommodate any type offastener.

FIG. 8 is an elevation view of the wall panel 300 connected to theclosed wall connector 100 with base boards 400 installed. As shown inFIG. 8, at least one base board 400 may be added to the bottom of thewall panel 300. The base board 400 on the sheathed side of the wallpanel 300 covers up the connection to the closed wall connector 100 andencloses or seals up the wall assembly. Although not shown, crownmolding or trim may be added to the top of the wall panel 300 to coverup the connection with the closed wall connector 100 at the ceiling andenclose or seal up the wall assembly. The baseboard or trim provide afinished look by concealing the closed wall connector 100.

FIG. 9 is a flow chart of a method of installing the closed wallconnector and the wall panel 600. The method 700 includes the step 710of receiving an “L” shaped bracket 200. The “L” shaped bracket 200includes the details and embodiments previously described. Inparticular, the “L” shaped bracket includes a vertical leg 210 and ahorizontal leg 220. The horizontal leg 220 includes a first plurality ofapertures 230 and the vertical leg 210 includes a second plurality ofapertures 260.

The method 600 includes the step 620 of connecting the horizontal leg220 of the “L” shaped bracket 200 to a base 250 a, 250 b, 250 c. Thehorizontal leg 220 may be connected to the base 250 a, 250 b, 250 c witha first plurality of fasteners 240 a, 240 b through the first pluralityof apertures 230. The base 250 a, 250 b, 250 c may be the floor, theconcrete foundation, and/or the ceiling. The shank of the fastener 240a, 240 b extends through the aperture 230 and the head or nut of thefastener 240 a, 240 b is tight against the horizontal leg 220. Thehorizontal leg 220 may be connected by driving, drilling, screwing, orhammering the fastener 240 a, 240 b through the aperture 230 into thebase 250 a, 250 b, 250 c, or if the fastener 240 b is a cast in placeanchor bolt, the horizontal leg 220 may be connected by sliding the endof the anchor bolt through the aperture 230 and screwing a nut onto theend of the anchor bolt.

The method 600 includes the step 630 of placing a wall panel 300 againstthe horizontal leg 220 and adjacent to the vertical leg 210 of the “L”shaped bracket 200. The wall panel 300 is placed in the “L” shapedbracket 200 so that the bottom or top of the wall panel 300 abuts thehorizontal leg 220 and the sheathing 320 abuts the vertical leg 210. Thewall panel 300 includes the details and embodiments previouslydescribed.

The method 600 also includes the step 640 of connecting the vertical leg210 of the “L” shaped bracket 200 to the wall panel 300. The wall panel300 is connected to the vertical leg 210 with a second plurality offasteners 242 through the second plurality of apertures 260. Aspreviously described, the second plurality of fasteners 242 extendsthrough the second plurality of apertures 260 and into the sheathing 320and the bottom plate 310 or the top plate 340. The shank of the fastener242 extends through the aperture 260 and the head or nut of the fastener242 is tight against the vertical leg. The vertical leg 210 may beconnected by driving, drilling, screwing, or hammering the fastener 242through the aperture 260 into the sheathing 320 and the bottom plate 310or the top plate 340. The method 600 may also include installing baseboards 400 at the bottom of the wall panel 300.

Having thus described in detail a preferred selection of embodiments ofthe present invention, it is to be appreciated and will be apparent tothose skilled in the art that many physical changes could be made to theclosed wall connector, the wall, and the method without altering theinventive concepts and principles embodied therein. The presentembodiments are therefore to be considered in all respects asillustrative and not restrictive, the scope of the invention beingindicated by the appended claims rather than by the foregoingdescription, and all changes which come within the meaning and range ofequivalency of the claims are therefore to be embraced therein.

What is claimed is:
 1. A closed wall connector comprising: an “L” shapedbracket, the “L” shaped bracket including a horizontal leg and avertical leg, the horizontal leg including a first plurality ofapertures, and the vertical leg including a second plurality ofapertures; a first plurality of fasteners configured to connect thehorizontal leg to a base through the first plurality of apertures; and asecond plurality of fasteners configured to connect the vertical leg toa wall panel through the second plurality of apertures.
 2. The closedwall connector of claim 1 wherein the base is a floor.
 3. The closedwall connector of claim 1 wherein the base is a foundation.
 4. The closewall connector of claim 1 wherein the base is a ceiling.
 5. The closedwall connector of claim 1 wherein the first plurality of fasteners is aplurality of anchor bolts and nuts.
 6. The closed wall connector ofclaim 1 wherein the first plurality of fasteners is a plurality ofscrews.
 7. A wall comprising: an “L” shaped bracket, the “L” shapedbracket including a horizontal leg and a vertical leg, the horizontalleg including a first plurality of apertures, and the vertical legincluding a second plurality of apertures; a first plurality offasteners connecting the horizontal leg to a base through the firstplurality of apertures; a wall panel including a bottom plate, a topplate, and sheathing; and a second plurality of fasteners connecting thevertical leg to at least one of the bottom plate, the top plate, and thesheathing through the first plurality of apertures.
 8. The wall of claim7 wherein the base is a floor.
 9. The wall of claim 7 wherein the baseis a foundation.
 10. The wall of claim 7 wherein the base is a ceiling.11. The wall of claim 7 wherein the first plurality of fasteners is aplurality of anchor bolts and nuts.
 12. The wall of claim 7 wherein thefirst plurality of fasteners is a plurality of screws.
 13. The wall ofclaim 7 wherein the wall panel further includes drywall.
 14. The wall ofclaim 13 wherein the drywall is held up from an end of the wall panel tofacilitate the connection with the vertical leg.
 15. The wall of claim 7wherein the bottom plate is routed out to accommodate the firstplurality of fasteners.
 16. The wall of claim 7 further including atleast one base board at an end of the wall panel.
 17. A method ofinstalling a wall comprising: receiving an “L” shaped bracket, the “L”shaped bracket including a horizontal leg and a vertical leg, thehorizontal leg including a first plurality of apertures, and thevertical leg including a second plurality of apertures; connecting thehorizontal leg to a base with a first plurality of fasteners through thefirst plurality of apertures; placing a wall panel against thehorizontal leg and adjacent to the vertical leg; and connecting the wallpanel to the vertical leg with a second plurality of fasteners throughthe second plurality of apertures.
 18. The method of claim 17 furtherincluding installing at least one base board at a bottom of the wallpanel.
 19. The method of claim 17 wherein the base is at least one of afloor, a foundation, and a ceiling.
 20. The method of claim 17 whereinthe first plurality of fasteners is a plurality of anchor bolts and nutsor a plurality of screws.